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OmniTurn GT-75 Installation, Operations, And Technical Documentation

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OmniTurn
Zip Loader Setup & Operations
Fast... Precise... Aff ordable...
Zip-Loader Installation, Operations,
and Technical Documentation for GT-75
(Including 1/16" Knife and Hopper Options)
Description
The OmniTurn Zip Loader is a multi-mode auto-loader that works as a short bar-loader or
as a part-loader.
Bars or parts are lifted one at a time from the tray (or hopper) onto a guide-trough, then
fed through the spindle liner into the collet.
Parts can be qualified from the face or from the rear, for overall length.
When the part is located, the collet is closed and the part is machined.
After machining, the part is ejected and the cycle begins again.
This document includes the hopper option and the 1/16" knife option.
The 1/16" knife is designed for loading parts or bars as small as 0.070" diameter.
The parts hopper option is designed to increase the number of parts that can be loaded
with the ZipLoader. The standard hopper accommodates parts from 1/2" diameter
to about 1/8". For hopper operation with parts as small as 0.085" diameter some
modification would be necessary.
Dec 2019
zipldr_setup&operations
Page 1 of 44
www.OmniTurn.com
support@OmniTurn.com
(541) 332-7004
(541)-332-1018 fax

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Summary of Contents for OmniTurn GT-75

  • Page 1 (Including 1/16” Knife and Hopper Options) Description The OmniTurn Zip Loader is a multi-mode auto-loader that works as a short bar-loader or as a part-loader. Bars or parts are lifted one at a time from the tray (or hopper) onto a guide-trough, then fed through the spindle liner into the collet.

  • Page 2: Table Of Contents

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Table of Contents Section 1: Component Descriptions Zip Loader w/Hopper: Major Components..3 Component Parts, Overview ....4 Component Parts, Sensors .

  • Page 3: Zip Loader W/Hopper: Major Components

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Zip Loader w/Hopper: Major Components Before using your Zip Loader, become familiar with the component parts Stack Lamp Tray Adjustable Tray Guide Rear-stop Shuttle Shuttle stop Home Stop Spindle Liner...

  • Page 4: Component Parts, Overview

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Component Parts, Overview Tray-guide Shoulders keep small diameter parts in tray from crawling over one another Adjustable Tray Guide is set to accommodate the length of parts in tray Knee is moved away from knife (not shown) as part diameter is increased Spindle Liner To change spindle liner, remove pushrod from shuttle, loosen tray-lock knob and remove micrometer lock knob,then pivot tray assembly out of the way.

  • Page 5: Component Parts, Sensors

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Component Parts, Sensors There are five magnetic sensors on the rodless cylinder as follows: Home: Mounted at left, farthest from collet closer, this sensor must light when the shuttle- plate is at the adjustable home stop. Move the adjustable home stop and “home” sensor as required to locate pusher just to left of part so as to minimize cycle-time.

  • Page 6: Component Parts, Air Panel

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Component Parts, Air Panel Pusher Speed, Slow Initial Setting: Full CW then 1-3/4 CCW pn 797-11-002 Knife Regulator “Push” Regulator Set at 35psi Set at 87psi pn 697-11-102 pn 697-11-102...

  • Page 7: Component Parts, Tray-Guide Shoulders

    If the loader or the CNC faults, the red “Reset/Initialize” Push Shuttle (right) pushbutton will illuminate. Pressing Reset when lit will open the collet on the GT-75, retract the rear-stop shot-pin and table-mounted stop, and retract the shuttle to home. Retract Shuttle (left)

  • Page 8: Component Parts, Tray Pivot

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Component Parts, Tray Pivot 1-1/8” alignment bar 1/4” part Pivot Bracket Tray Lock Bracket RED=Tray at lowest position GREEN=Tray raised for 1/4” part As tray pivots, centers of different diameter parts align with pusher and spindle-liner.

  • Page 9: Component Parts, Vee & Pushrod

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Component Parts, Vee & Pushrod Pushrod Adapter Spindle Liner Pushrod w/ Pusher Vee Front Shuttle Plate Knee Adjust Lock-knob Shuttle Bearings Tray Adjust Lock-knob When aligning the ZipLoader for parts with diameters 1/8” or less, simply rotating the tray assembly may not be satisfactory because the accuracy required to align the part with the liner is much higher for small parts.

  • Page 10: Pusher And Push-Rods

    DELRIN PUSHER, DIAMETER TO SUIT Push-rods for small diameter parts The OmniTurn ZipLoader is capable of loading parts as small as 0.089” in diamter, but special pushrods are necessary. For the smallest diameters, a thinner escapement knife is required. We stock the necessary components, or you can fab your own from our drawings.

  • Page 11: Vee & 1/8" Pushrod Adjustment

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... 1/8” Push-rod and Pushrod Adapter The drawing below describes the adapter plate that holds the pushrod to the shuttle plate, and the pushrod itself. The pushrod is any kind of 1/8” drillrod, bent to 90° as shown and cut to about 25.5”...

  • Page 12: Loader Setup And Alignment, Mechanical

    Fast... Precise... Aff ordable... Loader Setup and Alignment, Mechanical NOTE: If your ZipLoader shipped wih your OmniTurn, it was was aligned to the machine at the factory. The front leveling mounts and foundation brackets are properly set. Only the rear leveling mounts need adjustment to level the loader to the machine on your floor.

  • Page 13: Loader Setup And Alignment, Electrical

    Connect the small in-line connector and blue air-line marked “Table Stop” to the spring-loaded stop which is mounted on the tooling plate (table) in the GT-75. The stop can be moved to any location compatible with the other tooling. The spring-loaded stop is certainly necessary for the second op.

  • Page 14: Loader Setup And Alignment, Air

    11. Press “Push” switch; shuttle should move to your right; press “Retract” until shuttle returns to home. 12. Set Auto/Manual switch to Auto. Home the CNC and go to MDI mode. Front door of GT-75 must be closed or the door interlock bypass key-switch must be engaged; ziploader cover bypass key-switch on PLC cabinet must also be engaged.

  • Page 15: Loader Alignment And Changing Diameters

    ’vee’ assembly. With tray assembly is at its lowest position, set the load- er height so that 1-1/8” bar will slide easily into draw-tube on OmniTurn. If a liner is in- stalled, the same 1-1/8” bar can be used with tray assembly at lowest position, but a dowel that closely fits liner must be installed on center in bar.

  • Page 16: Aligning The Shuttle Plate Assembly

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Aligning the Shuttle Plate Assembly The shuttle assembly and rodless cylinder should be periodically checked for correct align- ment with the ‘vee’. This must be done if the rodless cylinder is replaced.

  • Page 17: Aligning The Loader For Small Diameter Parts

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Aligning the loader for Small Diameter Parts See Page for 1/8” pushrod description (1/16” knife option) When loading parts with diameters 5/16 and greater, the push-rod is fitted with a delrin push- er which is the about the same diameter as the part, or a little smaller.

  • Page 18: Section 3: Hopper

    Fast... Precise... Aff ordable... Hopper Operational Description The parts hopper is designed to be used with the Omniturn Zip Loader to increase the number of parts that can be loaded with the ZipLoader. The hopper allows small diameter parts (1/2” - 1/8”) to be loaded in quantity in a 3-1/2”h x 11-3/4” x 24-1/8” wide box, the quantity depending on the diameter of the part.

  • Page 19: Hopper Adjustments, 1/8" And 1/16" In Knife

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Hopper Adjustments, 1/8” and 1/16” in Knife FRONT GATE LIP to KNEE: So back of part just clears lip as knife raises. Hopper installed on standard Ø.625 KNEE parts 1/8” knife ZipLoader setup for loading 5/8”...

  • Page 20: Using The Loader

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Using the Loader Set the Adjustable Home Stop so that the pusher clears the bar or part when the shuttle is firmly against the stop. The Home sensor must light when shuttle is firmly against the stop.

  • Page 21: All Modes

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... All Modes Overview of Operation Common Features The ZipLoader will handle bars or parts up to 25 inches long and 1/8” to 1-1/16” in diameter. Bars or parts are loaded into the tray. An optional hopper is available for parts up to 21 inches long and 3/4”...

  • Page 22: Bar Mode (M50)

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Bar Mode (M50) Component Parts and Setup SET-UP ZipLoader Put bar in collet at correct length. BAR MODE Set bar stop at face. Set Slow sensor to light just before bar stop with full bar.
  • Page 23 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Bar Mode (M50) Operation and M-functions LOAD FIRST BAR BY HAND Bar Stop on Table New bar loaded by hand FEED LOAD FIRST BAR BY HAND M11: Opens Collet Starts to feed...
  • Page 24 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Bar Mode (M50) Programming Use M50 to set Bar mode; M11 to open collet and feed loaded bar. (Load first bar by hand) Use M97 to check for End of Bar, and to check for no bar (empty magazine).

  • Page 25: Part Mode (M51)

    1. Hard Stop (1): As with “ Bar Mode” this is a hard stop mounted at a tool position on the tooling plate (table) of the OmniTurn. 2. Spindle Liner (2): The liner should be .020 - .040 larger than the bar to insure vibration-free opera- tion and reliable feeding.
  • Page 26 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Part Mode (M51) Operation and M-functions M47 -1: LOAD Opens Collet Next part escaped Shuttle goes Home to 'vee' Escapes part to 'vee' Home InPlace Home sensor lit M47 -2:...
  • Page 27 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Part Mode (M51) Programming VERY IMPORTANT: (1) Part stop must be in position before M47. (2) “In Place” sensor should light about .050” before face of part hits hard stop.
  • Page 28 PLC to close the collet, and stop pushing. Locate Hard Stop To Position the Stops: 1. Set the OmniTurn in Jog mode. 2. Locate the hard stop about where you want the face of the part 3. Set this as a tool number (you can adjust offsets precisely later) 4.
  • Page 29 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Stop Mode (M52) Component Parts and Setup Setup: QUALIFY REAR QUALIFY REAR ZipLoader Put part in collet at correct length. With pusher against part, locate Shuttle Stop . STOP MODE STOP MODE Set InPlace sensor to light.

  • Page 30: Stop Mode (M52)

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Stop Mode (M52) Operation and M-functions M47 -1: Part Located Sensor LOAD NEW PART Opens Collet Part escaped to 'vee' Escapes part to 'vee' Pusher Spring-Loaded Stop on table Move Spring-Loaded Stop...
  • Page 31 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Stop Mode (M52) Programming VERY IMPORTANT: (1) Spring-loaded stop must be in position before M47. (2) With shuttle at shuttle stop and part in liner, spring-loaded stop should compress about 0.075”.
  • Page 32 6. Issue M49 to press shuttle dog against pin. 7. Set the OmniTurn to Jog mode: Jog the tooling plate in X and Z so that tip of spring-loaded stop is com- pressed about .050 - .150”. Loosen screw on band, and adjust sensor on cylinder so “Part Located”...

  • Page 33: 2Part Mode (M53)

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... 2Part Mode (M53): Qualify Face Component Parts and Setup SET-UP Program starts with part in collet. Put part in collet at correct length. ZipLoader Locate shuttle at Front Stop. Part in Dead-Length Collet Set InPlace Switch to light.

  • Page 34: Plc Faults

    If it is ever necessary to restore the PLC program for the Zip Loader, follow these steps: 1. From Auto Mode on the OmniTurn select F3 “Edit Program” (any program in memory) 2. From the program editor screen select F1, the F4 “Shell to DOS”...

  • Page 35: M-Functions

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... M-Functions M-functions used in programs: m10 (in bar mode): close collet and stop feed m11 (in bar mode): open collet and start feed m42: push slow; use to double feed, or for slow eject in part mode (see page 19 for details)

  • Page 36: M97 - Jump To Sub-Routine, Conditional

    Fast... Precise... Aff ordable... M97 - Jump to Sub-routine, Conditional For reference, the following information is taken from the OmniTurn Manual page describing the conditional sub-routine M97. M97 is used to cause the part program to execute a sub-routine in response to an input from an external source, like a bar-feeder or auto-loader.

  • Page 37: Air Panel Parts List

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Air Panel Parts List Mini Regulator 0-100 psi 697-11-102 Mini Regulator 0-60 psi Pressure Relief Valve 797-11-001 697-11-021 ZL1219 Solenoid Valve 797-15-001 (5) Flow Control 797-11-002 (2) Regulator/Filter 697-11-015 Misubishi PLC FX1s-30MR...

  • Page 38: Shuttle Components Parts List

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... Shuttle Components and Spring-loaded Stop Parts List    zipldr_setup&operations Page 38 of 44 www.OmniTurn.com support@OmniTurn.com (541) 332-7004 (541)-332-1018 fax...

  • Page 39: Section 5: Technical Documents

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable...    zipldr_setup&operations Page 39 of 44 www.OmniTurn.com support@OmniTurn.com (541) 332-7004 (541)-332-1018 fax...
  • Page 40 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... G4 CNC See next page for G3 CNC    zipldr_setup&operations Page 40 of 44 www.OmniTurn.com support@OmniTurn.com (541) 332-7004 (541)-332-1018 fax...
  • Page 41 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... G3 CNC See previous page for G4 CNC    zipldr_setup&operations Page 41 of 44 www.OmniTurn.com support@OmniTurn.com (541) 332-7004 (541)-332-1018 fax...
  • Page 42 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... KEY SW: BYPASS G4 CNC SPINDLE DRIVE PWB ZIP CVR INTERLOCK (CURRENT)    zipldr_setup&operations Page 42 of 44 www.OmniTurn.com support@OmniTurn.com (541) 332-7004 (541)-332-1018 fax...
  • Page 43 OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... PLC Panel Label TB301 INPUTS Inputs: Programming: X0 = E-Stop from CNC M10 = Stop Feed Close Collet* X1 = Knife is Up X2 = Knife is Down M40 = Knife Up...

  • Page 44: Index

    OmniTurn Zip Loader Setup & Operations Fast... Precise... Aff ordable... This page intentionally blank    zipldr_setup&operations Page 44 of 44 www.OmniTurn.com support@OmniTurn.com (541) 332-7004 (541)-332-1018 fax...

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